ML20205N034
| ML20205N034 | |
| Person / Time | |
|---|---|
| Site: | Brunswick  |
| Issue date: | 03/13/1987 |
| From: | Blake J, Coley J NRC OFFICE OF INSPECTION & ENFORCEMENT (IE REGION II) |
| To: | |
| Shared Package | |
| ML20205N001 | List: |
| References | |
| 50-324-87-04, 50-324-87-4, 50-325-87-04, 50-325-87-4, NUDOCS 8704020565 | |
| Download: ML20205N034 (10) | |
See also: IR 05000324/1987004
Text
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UNITED STATES
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NUCLEAR REGULATORY COMMISSION
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101 MARIETTA STREET, N.W.
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Report Nos.: 50-325/87-04 and 50-324/87-04
Licensee: Carolina Power and Light Company
P. O. Box 1551
Raleigh, NC 27602
Docket Nos.:
50-325 and 50-324
License Nas.:
Facility Name:
Brunswick 1 and 2
Inspection Conducted:
February 23-27, 1987
Inspector:
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__ 3 -12-87
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J.
rey
Date Sig ed
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Approved by:
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J. J B1 kti, Chief
Date Signed
Mat i
s and Processes Section
Di
si n of Reactor Safety
SUMMARY
Scope:
This routine, unannounced inspection was conducted in the areas of
inservice inspection (Generic Letter 84-11), and welding activities for the
existing weld overlay repairs.
Results: One violation was identified - Failure to Follow Welding Procedure
Specification Parameters
paragraph 7.e.
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B704020565 870318
ADOCK 05000324
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REPORT DETAILS
1.
Persons Contacted
Licensee Employees
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C. R. Dietz, General Manager
- J. W. Chase, Assistant to General Manager
- J. A. Smith, Director, Administrative Support
- M. B. Kesmodel, Supervisor, Document Control
- E. R. Eckstein, Manager, Technical Support
- J. Titrington, Supervisor, Engineering
- L. Wheatley, Project Engineer Inservice Inspection
- W. J. Dorman, Supervisor, Quality Assurance
- K. E. Enzor, Director, Regulatory Compliance
- R. M. Poulk, Senior Specialist, Regulatory Compliance
- G. J. Oliver, Manager, Site Planning and Control
- T. H. Wyllie, Manager, Engineering and Construction
- W. Murray, Corporate Licensing
Other licensee employees contacted included engineers, technicians,
operators, mechanics, security force members, and office personnel.
NRC Resident Inspector
- B. Ruland, Senior Resident Inspector
- Attended exit interview
2.
Exit Interview
The inspection scope and findings were summarized on_ February 27, 1987,
with those persons indicated in paragraph 1 above.
The inspector
described the areas inspected and discussed in detail the inspection
findings.
No dissenting ' comments were received from the licensee. The
following new item was identified during this inspection.
(0 pen) Violation 325/87-04-01, Failure to Follow Welding Procedure
Specification Parameters, paragraph 7.e.
The licensee did not identify as proprietary any of the materials provided
to or reviewed by the inspector during this inspection.
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3.
Licensee Action on Previous Enforcement Matters
This subject was not addressed in the inspection.
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4.
Unresolved Items
Unresolved items were not identified during the inspection.
5.
Independent Inspection Effort
Construction Progress
The inspector conducted a general inspection of the Unit 1 Reactor-
Building and Rod Shack B to observe construction progress and construction
activities such as welding, material handling and control, housekeeping
and storage.
Within the areas examined, no violations or deviation were identified.
6.
Inservice Inspection (ISI)
During the current Brunswick 1, Reload 5, Outage, Carolina Power and Light
(CP&L) has divided the scope of the ISI work among the following vendors
and CP&L organizations:
(1) General Electric (GE) will perform code and
augmental ultrasonic examinations, (2) CP&L's Corporate Quality Assurance
Department (Materials and Quality Section) will perform the surface.
examinations, (3) Site Quality Control (QC) will perform the visual
examinations and, (4) CP&L will perform the existing overlay repairs using
Power Cutting Inc. welding operators that :have been qualified to _ CP&L's
welding procedures.
The inspector examined documents, activities, and records of each of
the above vendor /CP&L organizations to determine whether ISI was being
conducted in accordance with applicable procedure, regulatory requirements
and licensee commitments. The applicable code for 2nd intervals examina-
tions is the American Society of Mechanical Engineers Boiler 'and Pressure
Vessel (ASME B&PV) Code Section XI,1980 edition winter 1981.
However,
since CP&L started the 2nd interval early in order to have both Units
utilizing the same code edition, 1st interval examinations completed
during this outage will be performed in accordance with ASME B&PV Code,
Section XI, 1977 edition with addenda through summer 1978,
a.
Review of Procedures (73052) Units 1&2
i
The inspector reviewed the procedure indicated below to determine -
whether the procedures were consistent with regulatory requirements
and licensee commitments. The procedures were also reviewed in the
area of procedure approval, requirements for. qualification of non-
destructive examination (NDE) personnel, and compilation of required
records; and if applicable, division of responsibility between the
licensee and contractor personnel. Welding procedures used to perform
the existing weld overlay repairs on the recirculation system will be
discussed in detail on paragraph 7 of this report. The following ISI
examination procedures were reviewed:
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Organization
Procedure ID/ Title
UT-51, Revision 2, Procedure for Automated
Ultrasonic Examination of Dissimilar Metal
UT-30, Revision 15, Procedure for Ultrasonic
Examination of Austenitic Welds for IGSCC.
UT-43, Revision 9, _ Procedure for Ultrasonic
Examination of Pipe Welds Using Automated
Equipment.
NDEP-10, Training, Qualification and Certi-
fication
of
Nondestructive
Examination
Personnel, Revision 7.
NDEP-20,
Training,
Qualification
and
Certification
of
Visual
Examination
Personnel
for
Inservice
Inspection,
Revision 4.
NDEP-201,
Liquid
Penetrant
Examination
(Visible Dye, Solvent Removable)
Revision 10.
NDEP-301, Magnetic Particle Examination (Dry
Powder, Prods or Yoke) Revision 6.-
NDEP-1000, Additional Examination Criteria
for PSI /ISI Surface Examinations, Revision 1.
NDEP-1010,
Recording
Data- from Direct
Visual,
Liquid
Penetrant and Magnetic
Particle Examinations, Revision 0.
NDEP-1011, Weld Joint Identification Marking
~
on Nuclear Power Plant Piping, Revision 0.
Site QC
NDEP-611, Revision 4, VT-1 Visual Examina-
tion of Nuclear Power Plant Components.
Site QC
NDEP-612, Revision 4, VT-2, Visual Examina-
tion of Nuclear Power Plant Plan Components.
Site QC
NDEP-613, Revision 5, VT-3, Visual Examina-
tion of Nuclear Power Plant Components.
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Organization
Procedure ID/ Title
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Site QC
NDEP-614, Revision 6, VT-4, Visual Examina-
tion of Nuclear Power Plant Components.
Site QC
Periodic
Test:
PT-91.0.52,
VT-3/VT-4
Examination of Component Supports.
(1) The inspector reviewed procedures UT-51, UT-30 and UT-43 to
ascertain whether they had been reviewed and approved in
accordance with the licensee's established QA procedures. The
procedures were reviewed for technical adequacy-and conformance
with ASME,Section V, Article 5 and other licensee commit-
ments/ requirements in the below listed areas:
type of
apparatus used; extent of coverage of weldments; calibration
'
requirements; search units; beam angles; DAC curves; reference
level for monitoring discontinuities; method for demonstration
penetration; limits for evaluating and recording indications;
recording significant indications and; acceptance limits.
(2) The inspector reviewed procedure NDEP-201 to ascertain whether
it had been reviewed and approved in accordance with the
licensee's established QA procedures.
The procedure was
reviewed for technical adequacy and conformance with ASME,
Section V, Article 6 and other licensee commitments / requirements
in the below listed areas: specified method; penetrant material
identification; penetrant materials
analyzed 'for
penetrant materials analyzed for total . halogens; acceptable
pre-examination surface; drying time; method of penetrant
application; surface temperature; solvent removal; surface
drying prior to developing; type of developer; examination
technique; evaluation technique; and procedure requalification.
(3) The inspector reviewed procedure NDEP-301 to ascertain whether
it had been reviewed and approved in accordance with the
licensee's established QA procedures.
The procedure was
,
reviewed for technical adequacy and for conformance with
ASME Section V, Article 7,
and other licensee commitments /
requirements in the below listed areas:
examination method;
contrast of dry powder particle color with background; viewing
conditions; examination overlap and directions; pole or prod
spacing; current or lifting power (yoke) and; acceptance
l
criteria.
(4) The inspector reviewed visual examination procedures N0EP.611,
NDEP.612, NDEP.613, NDEP,614 and PT-91.0.52 to determine whether
they contained sufficient instructions to assure that the
following parameters were specified and controlled within the
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limiti permitted by the applicable code, standard, or any
additional specification requirement: method - direct visual,
remote visual or translucent visual; application - hydrostatic
testing, fabrication procedure, visual examination of welds,
leak testing, etc.; how visual examination is to be performed,
type of surface condition available; method or tool for surface
preparation, if any; whether direct or remote viewing is used;
special illumination, instruments, or equipment to be used, if
any; sequence of performing examination, when applicable; data
to be tabulated, if any acceptance criteria is specified and
consistent with the applicable code section or controlling
specification; and report form completion.
b.
Examiner Qualifications (73052 & 73753)
The inspector reviewed the qualification documentation for the
below listed NDE examiners in the following areas: employer's
name; person certified; activity qualified to perform; effective
period of certification; signature of employer's designated
representative, basis used for certification; and annual visual
acuity, color vision examination and periodic recertifica-
tion.
Method Level
Examiners
E.B.
III
III
III
J.H.C.
II
II
II
J.M.G.
II
II
II
L.P.J.
II
II
II
A.D.L.
II
II
II
D.R.L.
II
II
II
II
E.W.M.
II
II
II
N.V.P.
II
II
I
II
G.M.T.
II
II
II
II
II
(2) General Electric
The inspector verified GE's ultrasonic examiner qualifications
for the inspector of intergranular stress corrosion cracking
(IGSCC) in accordance with EPRI/BWROG/NRC training and qualifica-
tion agreement.
This was done by comparing GE's personnel
status log against EPRI's monthly qualification status summary.
The following individuals were certified as follows:
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Method Level-
EPRI
Data
Data
Name
Sizer
O' Lay
Coll.
Analysis
R. Anderson
II
x
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R. Bendele
II
x
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x
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R. Bonniwell
II
x
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B. Bouck
II
x
x
x
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J. L. Briggs
III
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x
-
T. L. Brinkman
III
x
x
x -
x
T. R. Brinkman
III
x
x
x
x
x
J. P. Carson
II
x
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E. Catron
II
x
B. M. Dummer
III
x
x
x
x
x
M. Evich
II
x
V. Gruno
II
x
T. Kimball
II
x
x
x
x
B. Lester
II
x
x
x
x
W. Money
II
x
x
R. Parr
II
x
R. A. Seals
III
x
x
x
x
)
S. Whiddon
II
x
x
x
T. R. White
II
x
x
x
x
c.
Observation of Work Activities - Unit 1 (73753)
Generic Letter 84-11 initiated a reinspection program for piping
susceptible to IGSCC.
In accordance with the above guidance CP&L
plans to perform the following inspection during the present Unit i
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refueling outage:
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(1) unrepaired austenitic stainless steel welds
(2) IE Notice 84-41 inconel butter welds
(3) existing weld overlay repairs
The inspector observed the following in process examinations on the
inconel butter welds:
Weld No. IB32-12-BR-K6
Weld No. 1832-12-BR-J6
In addition to the above, the inspector reviewed video tape of the
examinations performed on the following welds:
Weld No. 28" B32A-1 inconel butter examination
Weld No. 28 B32A-3 IGSCC examination
The above welds were examined with the GE SMART UT system using
examiners qualified in accordance with the EPRI/BWR06/NRC Training
and Qualification Agreement.
Within the areas examined, no violation or deviation was identified.
7.
Existing Weld Overlay Repairs - Unit 1 (73753 & 55055)
There are currently 32 weld overlay repairs on Brunswick-1. These are
designed repairs; however, as-built dimensions show that many meet the
standard guidance as propcsed in the draft of NUREG-0313 Revision 2.
The
length and surface finish of these repairs do not allow UT inspection
using the EPRI qualified technique; therefore, reinspection will require
lengthening and surface finishing prior to the UT examination. Ten of the
repairs on Brunswick-1 were applied in 1983 and 1984 and have been in
service for two fuel cycles. The remaining 22 repairs were applied during
the 1985 Reload 4 outage and, as such, will have been in service for only
one cycle.
CP&L plans to upgrade the ten repairs applied in 1983 and 1984 such that
inspections can be accomplished using the EPRI qualified UT technique.
Upgrading these weld overlay repairs consists of adding length and
thickness to the overlay, as required, and performing surface finishing.
CP&L has endorsed a NUTECH analysis which justifies continued operation of
Brunswick-1 for an additional 18-month fuel cycle without upgrade or
inspection of 21 of the 22 weld overlay repairs applied in 1985. As
recommended by the report, the licensee will upgrade and inspect weld
12"-B32-BR-J-3.
In addition, the licensee plans to upgrade and inspect as
many of the remaining 21 repairs applied in 1985 as possible without
impacting the outage critical path.
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The inspector reviewed the licensee's welding program, procedure, procure-
ment, qualifications activities, filler material control and storage and
in process welding activities to determine whether the licensee quality
control systems met the applicable procedure, regulatory requirements
and a licensee commitments. The applicable code for the overlay repair
welding is ASME,Section IX, the mandatory edition and addenda in effect
on the date of the welding procedure qualification.
New procedures,
evaluation procedures and acceptance criteria for austenitic piping is
ASME Code Section XI paragraph IWB-3640 and Section IX, 1983 Edition with
Addenda thru Winter 1983.
a.
Review of Procedures
The inspector reviewed the procedure indicated below to determine
whether the procedures were consistent with regulatory requirements
and licensee commitments.
The procedures were also reviewed in the
areas of procedure approval, and compilation of required records:
Procedure ID
Title
Plant Model 86-068
Existing Weld Overlay Repairs
WP-502 Revision 9
Welding Procedure Control
WP-503 Revision 11
Welder Qualification
WP-510 Revision 4
Qualification of Welding Procedure
Specification
WP-511 Revision 2
Welding Equipment Control
WP-501 Revision 5
Procurement of Welding Materials
b.
Base Materials & Filler Metal Compatibility
The inspector reviewed purchasing and receiving records for the
filler material used to repair the weld overlays (P.O. B-31925, Heat
No. S8t'530, ER-308L(.035)) and verified that the filler material was
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properly identified, storage and controlled in weld shack B.
c.
Welding Procedure Specifications
The inspector verified the licensee's welding specifications were in
accordance with Section IX and XI of the ASME Code, supported by
acceptable Procedure Qualification Reports (PQR's) that had received
the required mechanical test.
The following welding specifications
and their applicable PQR are listed below:
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Welding Procedure Specification / Effective Code
WPS-8BU7 Revision 0 - ASME (77579)
68
WPS-88U12 Revision 5 - AMSE (80W81)
33
WPS-43BU1 Revision 3 - AMSE (83584)
147
d.
Welder Performance Qualification
The inspector reviewed the qualification status for the weld
operators listed below and observed in process qualification efforts
for the overlay repair welding in the weld test shop.
Welder
WPS 8BV7
88V12
43BV1
P15
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P29
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P20
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P38
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YD8
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P16
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Y7G
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P10
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P18
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P12
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P34
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P5
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V1N
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e.
Production Welding
The inspe. tor observed in process repair welding activities on weld
overlays for weld numbers 28" B32-B-4 and 28" B32-A-4.
During this
observation, the inspector reviewed the plant modification require-
ments for these welds, welding filler material control records and
welding procedure parameters used by the welders to make the repair
welds. The inspector noted that the welder on weld 28" -1832-A-4 was
operating in the sync pulse mode and had his machine set at .05 for
the oscillation amplitude. The required welding procedure WPS-88U12
for this repair required that the oscillation amplitude ' be -set
between .06 and .200 when operating in the sync pulse mode.
Failure
to follow the qualified parameters of the welding procedure is a
violation of regulatory requirements and was reported to the licensee
as Violation 325/87-04-01, Failure to Follow Welding Procedure
Specification Parameters.
Within the area examined, no violations or deviations were identified,
except as noted in 7.e. above.